open call hpdc pilot line - lightme-ecosystem.eu
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Open Call – HPDC Pilot LineGuangyu Liu, Mahfuz Karim, Dmitry Eskin, Jon Gadd,
Brian McKay
BCAST, Brunel University London
11th February 2021
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Where is the HPDC pilot line
Isambard Kingdom Brunel
Founded 196615,000 students >100 countries
Schools in:•Engineering•Science•Business•Sports•Arts
Research Themes1806-1859
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BCAST - Brunel Centre for Advanced Solidification Technology
• Established in October 2002
• The research group comprises over 100 members of staff and students.
• Work closely with industrial partners, like Constellium University Technology Centre (UTC)
and Jaguar Land Rover (JLR) etc.
• Fundamental research to industrial applications on solidification and lightweight metals.
BCAST Overview
From atoms to applications
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Ingots Melting Degassing Casting Trimming
Quality check
• Composition
Quality check
• Temperature
Quality check
• Metallurgical
characterisations
• Mechanical
properties
Quality check
• Composition
• H-content
Quality check
• HPDC
parameters
• Monitoring (IR
Camera, GOM,
CT)
NPs
introduction
Quality check
• Mixing
• NPs distribution
• Thermal
analysis
RPT- H contentFoundry-Master (OES) Degassing and
mixing GOM
IR Camera
X-ray CT
HPDC pilot line workflows
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Research Facilities
• Wide range of casting lines (DC,
GDC, HPDC, LPDC, SC, TRC…)
• Mechanical testing (Hardness
indenter, tensile, bending,
fatigue …)
• Characterisations (GOM, x-ray
CT, SEM/EDS, TEM, XRD…)
Micro/Macro CT Scan X-Ray Diffraction
Zeiss Crossbeam (SEM) JEOL 2100 (TEM)
HPDC machine
HV indenter Tensile and fatigue
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HPDC pilot line
• Al Castings from 1.5 kg to 5 kg
• Mg Castings from 1 kg to 3 kg
• 2x 40 kg furnaces
• Ladled by hand
• Cycle times ~120 sec
• Pfeiffer Vacuum system, 50 to 70 mbar
• Max size of platen 1060×1060 mm
FRECH DAK 450-54
Vacuum channel 2
Vacuum channel 1
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• Al Castings from 8 kg to 32 kg
• 600 kg dosing furnace
• ABB robotics (IRC5 M2004)
• Typical cycle times 60-120 sec
• Vacuum assisted HPDC (50 -80 mbar)
• Vacural (high vacuum HPDC) 20-30mbar
• Max size of platen 1950×1950 mm
FRECH DAK 1680-133
HPDC pilot line
ABB Robotics
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HPDC PL in connection with other BBs
• Processing monitoring
• Process controlStam, ISQ, VISUM
• Structural characterization
• Functional properties testing
• Field tests
• Environmental impact
• LCA
• Process optimization
• Simulations
• Predictive modelling
Ubrun, Hidria, Vertech
ACCESS
This project has received funding from theIndustrial Technologies Advanced Materialsand Nanotechnologies under the EuropeanUnion’s Horizon 2020 innovation programmeunder the grand agreement number
814552.
Thank you for your attention